A power system for powering a load including a power converter and a control circuit coupled to the power converter. The power converter includes an input terminal for receiving an input voltage and an input current, and output terminal for outputting an output voltage and an output current to a load. The control circuit is configured to monitor the output voltage and the output current of the power converter and shut down the power converter in response to the output voltage being less than or equal to a defined voltage threshold and the output current being greater than or equal to a defined current threshold for a defined period of time. Other example power systems, control circuits, and methods of controlling power converters are also disclosed.
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13. A method of controlling a power converter, the method comprising:
shutting down a power converter in response to an output voltage of the power converter being less than or equal to a defined voltage threshold for a defined period of time and an output current of the power converter being greater than or equal to a defined current threshold for the defined period of time.
20. A control circuit for controlling a power converter, the control circuit configured to monitor an output voltage and an output current of the power converter, and to shut down the power converter in response to the output voltage being less than or equal to a defined voltage threshold for a defined period of time and the output current being greater than or equal to a defined current threshold for the defined period of time.
1. A power system for powering a load, the power system comprising:
a power converter having an input terminal for receiving an input voltage and an input current, and output terminal for outputting an output voltage and an output current to a load, and
a control circuit coupled to the power converter, the control circuit configured to monitor the output voltage and the output current of the power converter and shut down the power converter in response to the output voltage being less than or equal to a defined voltage threshold for a defined period of time and the output current being greater than or equal to a defined current threshold for the defined period of time.
3. The power system of
4. The power system of
6. The power system of
7. The power system of
14. The method of
17. The method of
18. The method of
19. The method of
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This application claims the benefit and priority of U.S. Provisional Application No. 62/200,437 filed Aug. 3, 2015. The entire disclosure of the above application is incorporated herein by reference.
The present disclosure relates to power converters and methods for controlling power converters.
This section provides background information related to the present disclosure which is not necessarily prior art.
Power converters such as rectifiers provide power to a load. Typically, these power converters include components to protect themselves and/or the load from undesirable circumstances. For example, the power converters are sometimes controlled to shut down (e.g., latch off) when its regulated output voltage falls below a particular setpoint.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
According to one aspect of the present disclosure, a power supply includes a power system for powering a load. The power system includes a power converter and a control circuit coupled to the power converter. The power converter includes an input terminal for receiving an input voltage and an input current, and output terminal for outputting an output voltage and an output current to a load. The control circuit is configured to monitor the output voltage and the output current of the power converter and shut down the power converter in response to the output voltage being less than or equal to a defined voltage threshold and the output current being greater than or equal to a defined current threshold for a defined period of time.
According to another aspect of the present disclosure, a method of controlling a power converter includes shutting down a power converter in response to an output voltage of the power converter being less than or equal to a defined voltage threshold and an output current of the power converter being greater than or equal to a defined current threshold for a defined period of time.
According to another aspect of the present disclosure, a control circuit for controlling a power converter is configured to couple to a power converter, to monitor an output voltage and an output current of the power converter, and to shut down the power converter in response to the output voltage being less than or equal to a defined voltage threshold and the output current being greater than or equal to a defined current threshold for a defined period of time.
Further aspects and areas of applicability will become apparent from the description provided herein. It should be understood that various aspects of this disclosure may be implemented individually or in combination with one or more other aspects. It should also be understood that the description and specific examples herein are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts or features throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
According to one aspect of the present disclosure, a method of controlling a rectifier includes shutting down the rectifier in response to the output voltage being less than (<) to a defined voltage threshold and an output current of the rectifier being greater than (>) a defined current threshold for a defined period of time.
In some embodiments, the rectifier may be shut down in response to the output voltage being less than or equal to (≦) a defined voltage threshold and the output current being greater than or equal to (≧) a defined current threshold for a defined period of time.
In other embodiments, the method may include monitoring (e.g., sensing, sampling, etc.) one or more rectifier parameters and comparing these parameters to defined thresholds. For example, a method for controlling a rectifier according to one example embodiment of the present disclosure is illustrated in
Thus, and as explained herein, the rectifier is shut down (e.g., latched off, etc.) thereby disabling its output when the voltage condition, the current condition, and the period of time condition are met.
The methods disclosed herein may be implemented by a power system including any suitable rectifier. For example,
After the rectifier 202 is shut down (e.g., latched off), a power source can be disconnected from and then reconnected to the input terminal 206 of the rectifier 202. For example, after the rectifier 202 is shut down, a user may manually disconnect the power source from the rectifier 202. After a period of time, the user can manually reconnect the power source to the input terminal 206 of the rectifier 202. This disconnection and reconnection may be done, for example, by opening and closing a breaker between the power source and the rectifier 202. In some examples, the user can wait a defined period of time so that residual voltage stored in one or more components (e.g., capacitors, etc.) of the rectifier 202 can fall to substantially zero, monitor this residual voltage, etc. Once this residual voltage is substantially zero, the user can reconnect the power source to the input terminal 206. In other embodiments, a control circuit (e.g., the control circuit 204, etc.) may disconnect and/or reconnect the power source and the rectifier 202. This cycling of the input may cause the rectifier 202 to reset and/or possibly correct one or more condition(s) causing the undesirable output current Iout and output voltage Vout.
After the power source is reconnected, the control circuit 204 will restart the rectifier 202. At this time, the control circuit 204 can again monitor the output voltage Vout and the output current Iout of the rectifier 202, and shut down the rectifier 202 as before.
The control circuit 204 may shut down and/or restart the rectifier 202 by providing a control signal 212 to the rectifier 202. For example, and as shown in
In some example embodiments, one or more current protection devices employed for the rectifier 202 may be adjusted, removed, etc. when the control methods disclosed herein are employed. For example, the rectifier 202 may include current limit fold-back functionality which causes the output voltage Vout and the output current Iout to decrease in response to the load exceeding a maximum current. In such cases, the control circuit 204 may fix a current limit of the fold-back functionality. Thus, in the event the current limit fold-back functionality is triggered (which causes the output voltage Vout and the output current Iout to decrease), the output current Iout will not fall below the fixed current limit. Consequently, the output voltage Vout will stop decreasing when the output current Iout reaches this fixed current limit. As such, the output voltage Vout will not decrease below the defined voltage threshold which may cause the rectifier 202 to shut down as explained herein due to the current limit fold-back functionality.
This fixed current limit may be based on, for example, the defined voltage threshold. For example, the fixed current limit may be set such that the output voltage Vout will not decrease below the defined voltage threshold when the current limit fold-back functionality is triggered. In some embodiments, this fixed current limit may be below the defined current threshold. For example, the fixed current limit may be about 40 A or another suitable value and the defined current threshold may be about 44.6 A (as explained herein).
In some embodiments, the control circuit 204 may activate an alarm (not shown in
The alarm may be positioned adjacent the rectifier 202 and/or the control circuit 204. For example, one or more LEDs may be positioned on an exterior case of the rectifier 202 so that it is visible to a user passing by. Additionally and/or alternatively, the alarm may be positioned in a control room remote from the rectifier 202 and/or the control circuit 204. In such examples, the control circuit 204 may send a signal to the alarm notifying a user in the control room that the rectifier 202 has shut down and/or restarted.
The control circuit 204 may include one or more components for comparing the outputs (e.g., the output voltage Vout and the output current Iout) and the defined thresholds, and/or for determining an elapsed time. For example, and as shown in
As shown in
The timer 310 of
When the timer 310 reaches a defined period of time (e.g., as explained above), the timer 310 may output a signal to its corresponding rectifier, another component in the control circuit 304, etc. to latch-off the rectifier. For example, the timer 310 may include a comparator, be coupled to a comparator, etc. to compare the elapsed time and the defined period of time as explained above.
Similarly, the timer 310 may include another comparator, be coupled to another comparator, etc. to compare an elapsed time and a defined period of time related to the restarting the rectifier as explained herein.
Although
As further explained below, the methods disclosed herein may also be implemented by a power system including another suitable converter. For example,
Additionally, and as shown in
As shown in
As shown in
The timer accrues an elapsed time (t) which is compared to a defined period of time (block 410). If the elapsed time (t) is greater than or equal to the defined period of time (block 412), the rectifier 202 is shut down (block 414) as explained herein.
If, however, the elapsed time (t) is less than the defined period of time in block 412, the output voltage Vout and the output current Iout is compared to the defined voltage threshold V_th and the defined current threshold I_th again (blocks 402, 404). If the above mentioned voltage condition and current condition remain true (block 406), the elapsed time (t) continues to accrue from its starting point (e.g., bypassing the start timer block 408), and the new elapsed time (t) is compared to the defined period of time (block 410).
However, if one of the voltage condition and the current condition explained above is not true at any point (block 406), the timer is stopped (block 416). For example, if the output voltage Vout is greater than the voltage threshold V_th, or if the output current Iout is less than the defined current threshold I_th (block 406), the timer is stopped. After which, the output voltage Vout and the output current Iout can be compared (again) to the voltage threshold V_th and the defined current threshold I_th (blocks 402, 404). If the timer has not been started, the stop timer block 416 is bypassed. After the rectifier 202 shuts down (block 414 of
As explained above, the flow chart 500 of
If the input voltage is above a minimum startup voltage setpoint (e.g., a voltage threshold), the power converter is started (blocks 504, 506). If the input voltage is not above a startup voltage setpoint (block 504), the power converter is not started and the input voltage is evaluated again to determine if the input voltage is above the minimum startup voltage setpoint.
After the power converter is started (block 506), an output current of the power converter is compared to a maximum current setpoint (e.g., a defined current threshold). If the output current is below the maximum current setpoint (block 508), the output current is evaluated again to determine if the output current is at or above the maximum current setpoint. If the output current is at or above the maximum current setpoint (block 508), an output voltage of the power converter is compared to a latch-off voltage setpoint (e.g., a defined voltage threshold).
If the output voltage is above the latch-off voltage setpoint (block 510), the output voltage is evaluated again to determine if the voltage is below the latch-off voltage setpoint. If the output voltage of the power converter is below the latch-off voltage setpoint (block 510), a latch-off timer is started (block 512). Thus, once both the output voltage of the power converter is below the latch-off voltage setpoint (block 510) and the output current is at or above the maximum current setpoint (block 508), the latch-off timer is started (block 512) as explained herein.
The latch-off timer is monitored to determine if the elapsed time has reached a latch-off time setpoint (e.g., a defined period of time). Once the elapsed time has reached the latch-off time setpoint (block 514), the power converter is latched off (block 516) as explained herein, and therefore does not provide an output. Thus, for the power converter to latch-off, both the output voltage of the power converter is below the latch-off voltage setpoint (block 510) and the output current is at or above the maximum current setpoint (block 508) for a defined period of time as explained herein.
At this time, the input voltage may be removed from the input of the power converter (block 518). For example, and as shown in
Once the AC input voltage is removed (block 518), the input voltage of the power converter may be compared to a minimum startup voltage setpoint (block 520). This minimum startup voltage setpoint of block 520 may be the same or a different value than the minimum startup voltage setpoint of block 504.
If the input voltage is below the minimum startup voltage setpoint (block 520), the latch-off condition is reset (block 522). For example, the latch-off condition can be reset by one or more appropriate control signals provided by the control circuit 604 of
If, however, the input voltage is above the startup voltage setpoint (block 520), the latch-off condition is not reset and the power converter is not started. In such examples, the input voltage is evaluated again as explained above. Thus, in the example of
The comparisons between (a) the output current and the defined current threshold disclosed herein (e.g., the maximum current setpoint of
The rectifiers disclosed herein may include any suitable topology without departing from the scope of the present disclosure. For example, the rectifiers may include a full-wave rectifier employing various diodes (e.g., two diodes, four diodes, etc.), various switches (e.g., two transistors, four transistors, etc.), etc. The switches may include transistors such as power MOSFETs, etc.
Further, although the methods disclosed herein are described relative to a rectifier and a generic power converter, it should be understood that the methods may be used to control other power converters such as DC/AC inverters and DC/DC power converters having any suitable topology (e.g., a buck topology, a boost topology, a buck-boost topology; a full bridge topology, a half bridge topology, etc.) without departing from the scope of the present disclosure. The power converters (including the rectifiers disclosed herein) may regulate its output (e.g., an output voltage, etc.) at a particular setpoint (e.g., about 380 VDC).
The defined periods of time disclosed herein related to the rectifiers (or other power converters) shutting down (e.g., the shut down period of time) and the defined periods of time disclosed herein related to the rectifiers (or other power converters) restarting (e.g., the restart period of time) may be any suitable period of time. The periods of time may be the same or different. For example, the restart period of time may be less than the shut down period of time. In some embodiments, the restart period of time may be about 115 milliseconds and the shut down period of time may be about five minutes.
The defined voltage thresholds disclosed herein and the defined current thresholds disclosed herein may be any suitable value. For example, the defined thresholds may depend (at least partially) on the power converter being controlled, a load coupled to the power converter, etc. In some embodiments, the defined current threshold may be about 44.6 A or another suitable value, and the defined voltage threshold may be about 270V or another suitable value. Additionally, the defined thresholds may be predefined and stored in memory of the control circuit, may be adjustable based on one or more parameters, etc.
The control circuits disclosed herein may include an analog control circuit, a digital control circuit (e.g., a digital signal controller (DSC), a digital signal processor (DSP), etc.) as shown in
Additionally, it should be understood to those skilled in the art that one or more portions of the control circuits may be a digital control circuit disposed on an integrated circuit (IC). Further, the control circuits may be a control circuit within a power module (or the like) including a rectifier. In other embodiments, the control circuits may be external a power module.
The systems and/or methods disclosed herein may be employed in any suitable application including, for example, telecommunication applications, information technology applications, etc. For example, the systems and/or methods may be employed in one or more battery backup units and/or another suitable power supply of a power system, DC systems providing low and/or high voltage (e.g., 5 VDC, 12 VDC, 24 VDC, 48 VDC, 270 VDC, 400 VDC, etc.), etc. The systems may be employed in enclosures (e.g., data racks, server cabinets, etc.) including, for example, stationary and/or modular enclosures.
By employing the systems and/or methods disclosed herein, a power converter may be shut down in the event a fault occurs (e.g., on the power converter's output) that may not be detected in other protection systems. For example, the methods may cause a power converter to disconnect power from a load when the power converter's current is insufficient to trip a current protection device on the power converter's output. By doing so, the possibility of fire, electrical shock, etc. caused by the fault may be reduced compared to other known systems.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
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